scholarly journals Forecasting Machine Failure Using DMG and Weibull Analysis in an Automotive Industry: A Case Study

2021 ◽  
Vol 40 (2) ◽  
pp. 435-442
Author(s):  
Kamran Shah ◽  
Hassan Khurshid ◽  
Izhar Ul Haq ◽  
Shaukat Ali Shah ◽  
Zeeshan Ali
Keyword(s):  
Decision Making ◽  
Manufacturing Industry ◽  
Management Strategies ◽  
Fixed Time ◽  
Maintenance Management ◽  
Maintenance Cost ◽  
Weibull Analysis ◽  
Effect Analysis ◽  
Machine Failure ◽  
Computerized Maintenance Management System

In manufacturing or production setup, maintenance cost is one of the major portions of overall operating expenditure. It can vary between 15 to 60 percentage of overall cost for various industries including food related industries, iron, steel and other heavy industries. Such a high cost directly impacts manufacturing setup, profitability and sustainability in long run. In most of the industries, ineffective maintenance management can result in loss of capital and inefficient human resource deployment. This in turn affects the plants’ ability to manufacture quality products that are competitive in the market. Various maintenance management strategies including Operate to Failure (OTF), Design Out Maintenance (DOM), Skill Level Upgrade (SLU), ConditionBased Monitoring (CBM) and Fixed Time Maintenance (FTM) are used in industries for maximizing productivity. In recent years, Computerized Maintenance Management System (CMMS) has become an integral part of most of the industries so its importance and characteristics cannot be understated. While CMMS cannot live standalone, it requires some decision-making techniques to be equipped with. These techniques range from Failure Mode and Effect Analysis (FMEA) to Decision Making Grid (DMG). In this paper, concept of DMG has been applied to an automotive parts Manufacturing Industry in conjunction with Weibull analysis. Parallels are drawn between the results of DMG and Weibull analysis.

scholarly journals A Costing Analysis for Decision Making Grid Model in Failure-Based Maintenance

2011 ◽  
Vol 2011 ◽  
pp. 1-15 ◽  
Author(s):  
Burhanuddin M. A. ◽  
Sami M. Halawani ◽  
A. R. Ahmad
Keyword(s):  
Decision Making ◽  
Production Cost ◽  
Good Control ◽  
Fish Bone ◽  
Maintenance Cost ◽  
Economic Downturn ◽  
Repair Cost ◽  
Grid Model ◽  
Computerized Maintenance Management System ◽  
Costing Analysis

Background. In current economic downturn, industries have to set good control on production cost, to maintain their profit margin. Maintenance department as an imperative unit in industries should attain all maintenance data, process information instantaneously, and subsequently transform it into a useful decision. Then act on the alternative to reduce production cost. Decision Making Grid model is used to identify strategies for maintenance decision. However, the model has limitation as it consider two factors only, that is, downtime and frequency of failures. We consider third factor, cost, in this study for failure-based maintenance. The objective of this paper is to introduce the formulae to estimate maintenance cost. Methods. Fish bone analysis conducted with Ishikawa model and Decision Making Grid methods are used in this study to reveal some underlying risk factors that delay failure-based maintenance. The goal of the study is to estimate the risk factor that is, repair cost to fit in the Decision Making Grid model. Decision Making grid model consider two variables, frequency of failure and downtime in the analysis. This paper introduces third variable, repair cost for Decision Making Grid model. This approaches give better result to categorize the machines, reduce cost, and boost the earning for the manufacturing plant. Results. We collected data from one of the food processing factories in Malaysia. From our empirical result, Machine C, Machine D, Machine F, and Machine I must be in the Decision Making Grid model even though their frequency of failures and downtime are less than Machine B and Machine N, based on the costing analysis. The case study and experimental results show that the cost analysis in Decision Making Grid model gives more promising strategies in failure-based maintenance. Conclusions. The improvement of Decision Making Grid model for decision analysis with costing analysis is our contribution in this paper for computerized maintenance management system.

scholarly journals Risk Assessment of Horizontal Wet Etching Equipment System in Manufacturing Plant Industry

2020 ◽  
Vol 3 (1) ◽  
Author(s):  
Nor'ain Mohd Ramli ◽  
Siti Aslina Hussain
Keyword(s):  
Manufacturing Industry ◽  
Business Environment ◽  
Wet Etching ◽  
Maintenance Cost ◽  
Process Equipment ◽  
Effect Analysis ◽  
Performance Factors ◽  
Equipment Reliability ◽  
Critical Components ◽  
Mean Time

Maintenance is one of the important roles in the high technology manufacturing industry. It is related to the key performance factors of the company such as quality, productivity, and cost. To achieve these factors, a reliability plan should be implemented which helps to maximise production value by implementing successful asset maintenance. This research project aims to focus on the critical process equipment known as Horizontal Wet Etching Equipment (HWEE) used in the wet etching process. The components in the HWEE system were identified by referring to the process and instrumentation diagram (PID) of the equipment and were categorised in different modes. Data on mean time to repair (MTTR) and mean time between repairs (MTBF) were collected based on previous company records. The data were analysed using MAROS software. Failure Mode and Effect Analysis (FMEA) was done to understand the risk of each of the components. The result shows that piping and gearbox have the highest RPN with 126 and 105, respectively. This study helps to identify critical components and is able to help the company to improve equipment reliability and reduce maintenance cost. Corrective action can be implemented to reduce the RPN for both components. Thus, it would help the industry to increase the key performance and become more competitive in the business environment.

scholarly journals Perancangan Sistem Informasi Perawatan Mesin Pada PT XYZ

2017 ◽  
Vol 6 (1) ◽  
pp. 9
Author(s):  
Berry Yuliandra ◽  
Kushisa Atta Jaeba
Keyword(s):  
Information System ◽  
Data Management ◽  
Manufacturing Industry ◽  
Object Oriented ◽  
Maintenance Management ◽  
Maintenance Cost ◽  
Object Oriented Design ◽  
Related Data ◽  
Maintenance Activities ◽  
The Cost

<p>Maintenance management is an important aspect that define success and sustainability of a manufacturing industry. The development of information technology give new possibilities to improve maintenance management performance. Data management with the help from information system will improve maintenance management effectiveness and efficiency. PT XYZ is an industry specialized in retreading tires service. Preliminary study on machinery maintenance process in PT XYZ showed that breakdown and maintenance data were not properly documented. This can generate high cost for the company because maintenance scheduling cannot optimally determined and the cost incurred by repair and maintenance activities, and also the cost of lost production time cannot determined directly. Therefore PT XYZ need information system to improve their maintenance management efficiency. Information system designed in accordance with company need based on system survey and interview. The design of information system developed using Object Oriented Analysis (OOA) and Object Oriented Design (OOD) approach. The designed information system can help maintenance management implementation and related data management. The availability of repair and maintenance data can help factory supervisor to make decision related to maintenance activities such as parts needed and maintenance cost.</p><p>Keywords: maintenance, information system, performance </p>

Overall equipment effectiveness of tyre curing press: a case study

2017 ◽  
Vol 23 (1) ◽  
pp. 39-56 ◽  
Author(s):  
Faizan Saleem ◽  
Salman Nisar ◽  
Muhammad Ali Khan ◽  
Sohaib Zia Khan ◽  
Mohammad Aslam Sheikh
Keyword(s):  
Manufacturing Industry ◽  
Production Equipment ◽  
Maintenance Cost ◽  
Management Technique ◽  
Effect Analysis ◽  
Content Type ◽  
Manufacturing Plants ◽  
Before And After ◽  
Industrial Performance

Purpose The purpose of this paper is to formulate a benchmark to increase the tyre curing press production rate while minimizing tyre curing press downtime and maintenance cost with the help of a maintenance management technique based on overall equipment effectiveness (OEE). Design/methodology/approach The methodology is based on determining the OEE of tyre curing press before and after rectifying the causes of failures. The failure mode and effect analysis (FMEA) technique is used to find out the root causes of repetitive failures in tyre curing press by using the risk priority number. Findings A significant change in the value of OEE is observed after rectifying the repetitive failures, which were determined using the FMEA technique. Thus, it is concluded that the OEE and FMEA assist in improving the industrial performance and competitiveness of the production equipment studied. Research limitations/implications This study is limited to determining the OEE of single equipment only, not the whole production system. Manufacturing facilities are dependent on the operating environment; therefore a comparison of two different manufacturing plants based on the OEE value would not be justified. Practical implications This study can be applied in any tyre manufacturing industry in order to take competitive benefits, such as reduction in equipment downtime, increased production and reduction in maintenance cost. Originality/value The angle from which the paper approaches the bottleneck problem in a tyre production line is original for the studied company and shows positives results. It allows the company to apply the same approach in its other production equipment, lines and factories to achieve improvement in industrial performance and competitiveness.

A Highly Efficient and Optimised Simulation Based Multi objective Decision-Making for FMS Control

2018 ◽  
Vol 6 (6) ◽  
pp. 98
Author(s):  
Shreyanshu Parhi ◽  
S. C. Srivastava
Keyword(s):  
Decision Making ◽  
Real Time ◽  
Manufacturing Industry ◽  
Simulation Software ◽  
Shop Floor ◽  
Simulation Tool ◽  
Routing Flexibility ◽  
Decision System ◽  
Multi Objective ◽  
Arena Simulation

Optimized and efficient decision-making systems is the burning topic of research in modern manufacturing industry. The aforesaid statement is validated by the fact that the limitations of traditional decision-making system compresses the length and breadth of multi-objective decision-system application in FMS.  The bright area of FMS with more complexity in control and reduced simpler configuration plays a vital role in decision-making domain. The decision-making process consists of various activities such as collection of data from shop floor; appealing the decision-making activity; evaluation of alternatives and finally execution of best decisions. While studying and identifying a suitable decision-making approach the key critical factors such as decision automation levels, routing flexibility levels and control strategies are also considered. This paper investigates the cordial relation between the system ideality and process response time with various prospective of decision-making approaches responsible for shop-floor control of FMS. These cases are implemented to a real-time FMS problem and it is solved using ARENA simulation tool. ARENA is a simulation software that is used to calculate the industrial problems by creating a virtual shop floor environment. This proposed topology is being validated in real time solution of FMS problems with and without implementation of decision system in ARENA simulation tool. The real-time FMS problem is considered under the case of full routing flexibility. Finally, the comparative analysis of the results is done graphically and conclusion is drawn.

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